Method and apparatus for forming barrier ribs for use in flat panel displays

Abstract

Barrier ribs are formed on a back plate moved while a rib material is delivered thereto from a nozzle. Immediately after the rib material is delivered from the nozzle to the back plate, the rib material is irradiated with light to promote curing of the rib material. By promoting curing of the rib material with light emitted immediately after delivery of the rib material, the rib material delivered linearly to the back plate is maintained in shape. The rib forming process is thereby simplified to form barrier ribs with high quality and high accuracy. The rib material is used efficiently to achieve low cost. Besides, the barrier ribs may be formed to have a high aspect ratio.

What is claimed is:  
     
         1 . A method of forming barrier ribs on a back plate for use in a flat panel display, said method comprising: 
 a rib material delivery step for delivering a rib material from nozzle means while moving said nozzle means and said back plate relative to each other; and    a rib material curing step for curing said rib material on said back plate while delivering said rib material from said nozzle means.    
     
     
         2 . A method of forming barrier ribs for a flat panel display as defined in  claim 1 , wherein said rib material curing step is executed for curing said rib material by irradiating said rib material with light or heat, or supplying a hot blast thereto.  
     
     
         3 . A method of forming barrier ribs for a flat panel display as defined in  claim 1 , wherein said rib material curing step is executed for curing said rib material immediately after said rib material is delivered from said nozzle means to said back plate.  
     
     
         4 . A method of forming barrier ribs for a flat panel display as defined in  claim 2 , wherein said rib material curing step is executed for curing said rib material immediately after said rib material is delivered from said nozzle means to said back plate.  
     
     
         5 . A method of forming barrier ribs for a flat panel display as defined in  claim 1 , wherein said rib material delivery step is executed for delivering said rib material simultaneously from a plurality of discharge openings formed in said nozzle means.  
     
     
         6 . A method of forming barrier ribs for a flat panel display as defined in  claim 5 , wherein said rib material delivery step is executed for delivering said rib material from said nozzle means having a plurality of nozzles arranged in a direction perpendicular to a direction of relative movement, with ends of said nozzles partly overlapping each other.  
     
     
         7 . A method of forming barrier ribs for a flat panel display as defined in  claim 1 , wherein said rib material delivery step includes a rib material constant temperature delivery step for delivering said rib material from said nozzle means while moving said nozzle means and said back plate relative to each other, and while maintaining said rib material at a constant temperature.  
     
     
         8 . A method of forming barrier ribs for a flat panel display as defined in  claim 7 , wherein said rib material constant temperature delivery step is executed for delivering said rib material from said nozzle means, said rib material supplied being maintained at said constant temperature in or adjacent said nozzle means.  
     
     
         9 . A method of forming barrier ribs for a flat panel display as defined in  claim 7 , wherein said rib material constant temperature delivery step is executed for delivering said rib material from said nozzle means, said rib material supplied being maintained at said constant temperature in or adjacent said nozzle, lower than a temperature upstream thereof.  
     
     
         10 . A method of forming barrier ribs for a flat panel display as defined in  claim 1 , wherein said nozzle means defines discharge openings shaped longer in a direction of relative movement between said nozzle means and said back plate than in a direction perpendicular to said direction of relative movement.  
     
     
         11 . A method of forming barrier ribs on a back plate for use in a flat panel display, said method comprising: 
 a lift-off resist delivery step for delivering a lift-off resist from nozzle means to form relief patterns while moving said nozzle means and said back plate relative to each other;    a filling step for filling a rib material into spaces between said relief patterns;    a rib material curing step for curing said rib material; and    a removal step for removing said relief patterns;    the above steps being successively executed to form barrier ribs.    
     
     
         12 . A method of forming barrier ribs for a flat panel display as defined in  claim 11 , further comprising a lift-off resist curing step for curing said lift-off resist on said back plate while delivering said lift-off resist from said nozzle means.  
     
     
         13 . A method of forming barrier ribs for a flat panel display as defined in  claim 12 , wherein said lift-off resist curing step is executed for curing said lift-off resist by irradiating said lift-off resist with light or heat, or supplying a hot blast thereto.  
     
     
         14 . A method of forming barrier ribs for a flat panel display as defined in  claim 12 , wherein said lift-off resist curing step is executed for curing said lift-off resist immediately after said lift-off resist is delivered from said nozzle means to said back plate.  
     
     
         15 . A method of forming barrier ribs for a flat panel display as defined in  claim 13 , wherein said lift-off resist curing step is executed for curing said lift-off resist immediately after said lift-off resist is delivered from said nozzle means to said back plate.  
     
     
         16 . A method of forming barrier ribs for a flat panel display as defined in  claim 11 , wherein said lift-off resist delivery step is executed for delivering said lift-off resist simultaneously from a plurality of discharge openings formed in said nozzle means.  
     
     
         17 . A method of forming barrier ribs for a flat panel display as defined in  claim 16 , wherein said lift-off resist delivery step is executed for delivering said lift-off resist from said nozzle means having a plurality of nozzles arranged in a direction perpendicular to a direction of relative movement, with ends of said nozzles partly overlapping each other.  
     
     
         18 . A method of forming barrier ribs for a flat panel display as defined in  claim 11 , wherein said lift-off resist delivery step includes a lift-off resist constant temperature delivery step for delivering said lift-off resist from said nozzle means while moving said nozzle means and said back plate relative to each other, and while maintaining said lift-off resist at a constant temperature.  
     
     
         19 . A method of forming barrier ribs for a flat panel display as defined in  claim 11 , wherein said nozzle means defines discharge openings shaped longer in a direction of relative movement between said nozzle means and said back plate than in a direction perpendicular to said direction of relative movement.  
     
     
         20 . An apparatus for forming barrier ribs on a back plate for use in a flat panel display, said apparatus comprising: 
 nozzle means for delivering a rib material;    a support table for supporting said back plate;    moving means for moving said nozzle means and said support table relative to each other; and    curing means for curing said rib material delivered to said back plate;    wherein said rib material is delivered from said nozzle means while said moving means is operated to move said nozzle means and said back plate relative to each other, and said rib material on said back plate is cured by said curing means while said rib material is delivered from said nozzle means.    
     
     
         21 . An apparatus for forming barrier ribs for a flat panel display as defined in  claim 20 , wherein said curing means is arranged to cure said rib material by irradiating said rib material with light or heat, or supplying a hot blast thereto.  
     
     
         22 . An apparatus for forming barrier ribs for a flat panel display as defined in  claim 20 , wherein said curing means is disposed adjacent said nozzle means to cure said rib material immediately after said rib material is delivered from said nozzle means to said back plate.  
     
     
         23 . An apparatus for forming barrier ribs for a flat panel display as defined in  claim 21 , wherein said curing means is disposed adjacent said nozzle means to cure said rib material immediately after said rib material is delivered from said nozzle means to said back plate.  
     
     
         24 . An apparatus for forming barrier ribs for a flat panel display as defined in  claim 20 , wherein said nozzle means has a plurality of discharge openings for simultaneously delivering said rib material.  
     
     
         25 . An apparatus for forming barrier ribs for a flat panel display as defined in  claim 24 , wherein said nozzle means has a plurality of nozzles arranged in a direction perpendicular to a direction of relative movement, with ends of said nozzles partly overlapping each other.  
     
     
         26 . An apparatus for forming barrier ribs for a flat panel display as defined in  claim 20 , further comprising thermostat means for maintaining said rib material at a constant temperature, wherein said rib material is delivered from said nozzle means while moving said nozzle means and said back plate relative to each other, and while maintaining said rib material at said constant temperature.  
     
     
         27 . An apparatus for forming barrier ribs for a flat panel display as defined in  claim 26 , wherein said thermostat means is disposed adjacent said nozzle means to maintain said rib material at said constant temperature for delivery from said nozzle means.  
     
     
         28 . An apparatus for forming barrier ribs for a flat panel display as defined in  claim 26 , wherein said thermostat means maintains said rib material at said constant temperature in or adjacent said nozzle means, lower than a temperature upstream thereof, for delivery from said nozzle means.  
     
     
         29 . An apparatus for forming barrier ribs for a flat panel display as defined in  claim 20 , wherein said nozzle means defines discharge openings shaped longer in a direction of relative movement between said nozzle means and said back plate than in a direction perpendicular to said direction of relative movement.  
     
     
         30 . An apparatus for forming barrier ribs on a back plate for use in a flat panel display, said apparatus comprising: 
 nozzle means for delivering a lift-off resist to form rib-forming relief patterns;    a support table for supporting said back plate;    moving means for moving said nozzle means and said support table relative to each other;    filling means for filling a rib material into spaces between said relief patterns; and    removing means for removing said relief patterns;    wherein said lift-off resist is delivered from said nozzle means while said moving means is operated to move said nozzle means and said back plate relative to each other.    
     
     
         31 . An apparatus for forming barrier ribs for a flat panel display as defined in  claim 30 , further comprising curing means for curing said lift-off resist delivered to said back plate, wherein said lift-off resist is delivered from said nozzle means while said moving means is operated to move said nozzle means and said back plate relative to each other, and said lift-off resist on said back plate is cured by said curing means while said lift-off resist is delivered from said nozzle means.  
     
     
         32 . An apparatus for forming barrier ribs for a flat panel display as defined in  claim 31 , wherein said curing means is arranged to cure said lift-off resist by irradiating said lift-off resist with light or heat, or supplying a hot blast thereto.  
     
     
         33 . An apparatus for forming barrier ribs for a flat panel display as defined in  claim 31 , wherein said curing means is dispose adjacent said nozzle means to cure said lift-off resist immediately after said lift-off resist is delivered from said nozzle means to said back plate.  
     
     
         34 . An apparatus for forming barrier ribs for a flat panel display as defined in  claim 32 , wherein said curing means is dispose adjacent said nozzle means to cure said lift-off resist immediately after said lift-off resist is delivered from said nozzle means to said back plate.  
     
     
         35 . An apparatus for forming barrier ribs for a flat panel display as defined in  claim 30 , wherein said nozzle means has a plurality of discharge openings for simultaneously delivering said lift-off resist.  
     
     
         36 . An apparatus for forming barrier ribs for a flat panel display as defined in  claim 35 , wherein said nozzle means has a plurality of nozzles arranged in a direction perpendicular to a direction of relative movement, with ends of said nozzles partly overlapping each other.  
     
     
         37 . An apparatus for forming barrier ribs for a flat panel display as defined in  claim 30 , further comprising thermostat means for maintaining said lift-off resist at a constant temperature for delivery from said nozzle means, wherein said lift-off resist maintained at said constant temperature is delivered from said nozzle means while said moving means is operated to move said nozzle means and said back plate relative to each other, and said lift-off resist on said back plate is cured by said curing means while said lift-off resist is delivered from said nozzle means.  
     
     
         38 . An apparatus for forming barrier ribs for a flat panel display as defined in  claim 30 , wherein said nozzle means defines discharge openings shaped longer in a direction of relative movement between said nozzle means and said back plate than in a direction perpendicular to said direction of relative movement.